3D Printer Resin Vessel with Movable Support Scaffold
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Solution Overview
Problem
Three-dimensional printers optimized for photocurable materials are expensive and require excessive resin for large-scale printing, necessitating a reduction in resin usage while enabling the production of larger articles.
Innovation Solution
A system comprising a resin vessel with a transparent sheet, a light engine, a support scaffold with ridges to reduce unsupported dimensions, and a positioning actuator that moves the scaffold to allow selective curing of resin layers over a build plane, minimizing resin usage and enabling larger prints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large area build plane is provided for printing larger articles, then the printing capability is improved, but the resin consumption increases
Solution Approach 1:
The support scaffold is divided into multiple ridges that segment the build plane into distinct regions. These ridges create physical barriers that allow resin to be contained in smaller volumes while still enabling printing across a large build plane area. The ridges effectively partition the resin space, reducing overall resin consumption.
Solution Approach 2:
The support ridges extend vertically into the resin volume, creating a three-dimensional structure that partitions space. By adding this vertical dimension of support, the system reduces the horizontal spread of resin needed, effectively converting a two-dimensional resin layer problem into a three-dimensional managed volume solution.
2Area of stationary object
If the transparent sheet spans a large area to cover the build plane, then the coverage is improved, but the sheet becomes more prone to deformation and failure
Solution Approach 1:
The transparent sheet is supported by multiple discrete ridges that segment the load distribution. Instead of spanning the entire large area unsupported, the sheet rests on these distributed support points, reducing stress and preventing deformation while maintaining full area coverage.
Solution Approach 2:
The ridges provide localized support at specific positions beneath the transparent sheet. This local reinforcement strategy strengthens the sheet at critical points without requiring the entire sheet structure to be thicker or more robust, maintaining integrity across the large area.
3Ease of manufacture
If photocurable materials are used for three-dimensional printing, then the manufacturing capability is improved, but the material cost increases
Solution Approach 1:
The ridges segment the resin-containing regions, allowing photocurable material to be used only where needed for printing rather than filling the entire large build plane volume. This selective material placement reduces the quantity of expensive photocurable resin required while maintaining manufacturing capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces resin consumption by selectively curing layers and maintaining the transparency and integrity of the resin vessel, allowing for the production of larger three-dimensional articles with minimized material waste.
Implementation Method 1
The light engine is disposed below the transparent sheet and is configured to transmit or project radiation up through the transparent sheet. The projected radiation is for selectively curing layers of the resin over a laterally extending build plane.
Implementation Method 2
At a first lateral position the scaffold blocks the radiation from reaching a first blocked region of the build plane while allowing the radiation to reach a first unblocked region of the build plane.
Data Source
AI summary
A system for manufacturing a three-dimensional article includes a resin vessel, a light engine, a support scaffold, and a positioning actuator. The resin vessel includes an opening closed by a transparent sheet with opposed upper and lower surfaces. The light engine is disposed below the transparent sheet and is configured to transmit or project radiation up through the transparent sheet for selectively curing layers of the resin over a build plane. The support scaffold includes at least one ridge having an upper surface that contacts the lower surface of the transparent sheet to reduce an unsupported width. At a first lateral position the scaffold blocks the radiation from reaching a first blocked region of the build plane. The positioning actuator is configured to laterally move the scaffold from the first position to a second position to allow radiation to reach the first blocked region of the build plane.